This project is a concrete example of the integrated management of a highly complex international EPC contract. For the Fluor / JGC joint venture, Albizzati Group engineered and delivered five large-scale Field Auxiliary Rooms, fully prefabricated and integrated, managing the entire production cycle in-house and coordinating several manufacturing sites through to direct dockside loading at the port of Livorno.
The challenge
Delivering prefabricated technical structures of this scale is not just a production challenge, but one of coordination. In similar contexts, supplier fragmentation leads to inefficiencies, delays and operational risks. We addressed this complexity by applying our industrial model, a 100% in-house production cycle, ensuring full control over every phase of the project over its 20-month duration.
The main project challenges:
- Oversized module dimensions, up to 67 metres in length
- Modular design required to allow transport and final assembly
- Production distributed across several Group sites
- Preparation of fully prefabricated units for intercontinental shipment to Canada
Project breakdown
Through the full integration of engineering, production and preparation for shipment, we managed every phase of the project with operational continuity and centralised coordination.
Engineering and design
- Full development of the project engineering
- Direct technical coordination with the Fluor / JGC joint venture
- Modular design optimised for transport and final assembly
- Definition of plug-and-play configurations
Production and structural fabrication
- Fabrication of the structural steelwork at the Ossona facility
- Module production within road transport constraints
- Fully in-house structural processing
- Continuous quality control throughout the production cycle
Surface treatment and protection
- Surface preparation by sandblasting
- Application of certified coating systems
- Anti-corrosion protection for the LNG environment
- Inspection and control of coatings and finishes
Assembly and integration
- Pre-assembly of the modules at the Guasticce (Livorno) facility
- Progressive integration of the structures
- Final assembly at the port yard
- Full configuration of the units in plug-and-play mode
Testing and quality control
- Dimensional and structural inspections
- Welding and fabrication quality checks
- Preliminary functional testing
- Final validation prior to shipment
Packing and preparation for shipment
- Operational management of the yard at the port of Livorno
- Direct dockside loading of the modules onto the vessel
- Units prepared for shipment to Canada as fully prefabricated modules
The result
Five Field Auxiliary Rooms up to 67 metres long, delivered as plug-and-play units ready for installation at the LNG plant. The project demonstrates the Group’s ability to:
- Operate as a single point of contact for complex projects
- Manage distributed production across several sites and prepare oversized modules for international shipment
- Deliver plug-and-play solutions ready for installation
- Ensure full control over timelines, quality and coordination
Steelwork was fabricated under CSA W47.1, the Canadian welding certification held by both Albizzati S.p.A. and Alex Sistemi. Learn more about E-House electrical buildings and our 100% in-house production cycle, or contact us to discuss a project of this scale.
